Machining a Clutch Bushing with a Square Hole for a Monarch Model K Lathe

The square drive clutch handle on my Monarch Model K Lathe was worn to the point that it would barely work. To fix the problem, I machined a new bushing, including cutting a new square hole using a square broach and reinstalled it on the machine.
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[@hankthebugman]

There is something very soothing watching a stationary drill bit create a hole in a rotating mass of metal, with a long spiral chip departing through the bits flutes.

[@matthewsmith6435]

Thanks, Keith! Don't listen to the haters, great repair and instruction. I'm doing the same repair for my Series 61 Monarch. I'm using 932 bearing bronze for this part, and intending to replicate the original dutchman and 2 dowel pin arrangement. The factory part appears to be a copper coated cast iron part, with a 0.001" press fit (which i will replicate). Mine is also worn into a similar abomination. The series 60/61 handle also has sheet metal covers and felt wipers held on with retaining rings to help with swarf and grit and retain some lubricant.

[@garymucher9590]

I have always heard that if a person has a metal lathe and a milling machine, they can make/duplicate everything in their shop. Thumbs Up!

[@aubreyaub]

Should have made two of them. That way you will have a spare that you can't find in 5 years time!

[@aceroadholder2185]

Just put the spare on the rod and push it back to the support block on the end of the bed out of the way. On the Famco press, make a wooden tray or anything really with cardboard or rag padding to set on the floor under the press. Trust me when your nice new, very expensive broach falls through and snaps in two when it hits the concrete floor you will cry.

[@dadillen5902]

More like 200 years, if I'm judging the machines age and current used model (weekend warrior) as opposed to the designed use model (full scale production). The truly telling thing is that 80 plus years ago it was designed to be replaceable. How many machines designed today will last 80 years let alone be repairable.

[@richardhead8264]

There is something so satisfying about broaching. It's as if you're thumbing your nose at round holes.

[@stephenmorgan8510]

I love that lathe. It sounds so good.

[@afnDavid]

That thermometer on the wall was displaying a nice number. The Rucker has a cool shop!

[@morelenmir]

I must say I am a little disappointed there was no scraping required!!! Humour aside, a nice little video that covered several different, tough to describe techniques with exactly the right amount of detail to learn from. *Highly* enjoyable as always Keith!!!

[@carolcarola9719]

You are quite the mechanic! Watching your work keeps me motivated to complete my projects.

[@johnapel2856]

And it's done! Always enjoy the videos. Thanks.

[@leftturn99]

Glad to see it done and educational too.

[@elsdp-4560]

THANK YOU...for sharing. Nice repair.

[@rickpalechuk4411]

Nice one Keith, good for another 50 years. Thanks for sharing, Cheers

[@BruceBoschek]

There is always something really satisfying about watching a broach go through metal. At least I feel that way. That lathe is beautiful. I would love to be able to use it. Thanks so much for the update!

[@pneumatic00]

Sweet lathe, Keith. And painted my fave color for machinery.

[@kenzpenz]

Now that was interesting. Nice to see the ooops and the recovery with the desired result. Great video thanks for sharing you made my morning...Ken

[@InverJaze]

A lesson in just how much to take a job. Yes, it would have been better with a heat hardened part, possibly with a key-way cut out. On the other hand Keith could have just welded the old part with hard facing rods. None of that is necessary. Well done Keith, yet another demonstration in experience over what if.

[@hpda44]

Good to see that you’re actually doing some machining. I’ve missed that

[@cj7jeep81]

Nice video Keith, I need to make a couple for my old Monarch as well, so this is extremely helpful!

[@onestepatatime2346]

Nice work sir, a pleasure to watch

[@JustJimWillDo]

I love it when a plan comes together.

[@patrickdavey9692]

Love the true to life issues that we all come across no and then.

[@davidconaway2830]

As a long time woodworker, I've never seen a square broach and appreciate the way it works....little by little. I make square holes with a mortising machine and assumed a machinist used something similar. Thanks for the education!

[@migtrewornan8085]

Machinists can also use a rotary broach, metal shaper, filing machine and probably other methods. This is just one way.

[@RRINTHESHOP]

Nice repair Keith. Works great.

[@Jim-ie6uf]

I always enjoy your videos.

[@w6aav]

Very nice! Thanks for the great detail.

[@THEIRONWORKER]

Monacrh makes very good lathes and a nice restore on your lathe Keith

[@davidwright640]

How to put a square peg in a round hole? 12 ton Famco 5c arbor press.

[@MaturePatriot]

My ENCO 1340 has the same problem. Broaching makes life easier. I hate a sloppy fitting handle. Some good machining and fine entertainment.

[@capitanschetttino8745]

I love this channel.

[@firearmsstudent]

Even the greats screw up every now and then, good to see the bloopers!

[@ActiveAtom]

Hi Keith, thank you, Lance & Patrick

[@kennethbell7318]

As always Kieth you do a great job.

[@northfieldpiper]

Many thanks, always instructive, also entertaining

[@raincoast2396]

Like how you show the trials and tribulations Keith, being honest of how things go. Nice job.

[@boots7859]

Aside from AvE, TOT, and a number of others, I like this channel for simple and straight forward delivery and explanation. Would love to find a maker space locally that I could learn on.

[@waynephillips2777]

Great work!

[@joegarrett7580]

Great video. I need to do the same on my 12KK Monarch.

[@calliemaritz3401]

Great vid as always!!

[@dougguynn2622]

enjoyed as always

[@jeremycaylor9151]

Wow, that Famco arbor press was made just 10 minutes South of where I live! Pretty neat seeing that in one of your videos.

[@Hoaxer51]

Nice little 20 minute job for Monday morning! Makes you wonder why you didn’t do it sooner!

[@Blackcountrysteam]

There's nothing like having the right bit of kit when you need it :-) nice job.

[@perjohansson4402]

Nice sharp drills.

[@ScottandTera]

Great little fix... did anyone else see the table flexing on the arbor press or were my eyes playing tricks on me

[@bobberry6028]

Yes, noticed the same thing and wondered how heavy the bed was on the press.

[@jesusjacobo3423]

Easy and quick fix 👍🏽

[@Throughthebulkhead]

What a pleasure it is to use machines to fix themselves! The knee of the arbor press seemed to be flexing ?

[@wuudturner]

Keith never fails to post a great video, where I find much to learn. It is always a pleasure to see he has posted a new one. One question though, I am always surprised to see some old style box end wrenches used, whereas a set of ratcheting box end wrenches make most jobs go faster. So, is it that the ratcheting wrenches do not let you into some tight spots, or is it that the ratchets fail eventually? In my own admittedly light use, that has never been an issue for me.

[@railfan439]

Like was said below, I wonder why Monarch didn't use a flat point set screw and a small flat on the external of that bushing. Sure saves multiple drilling of the handle/bushing combination. See you at the Bar-Z. Jon

[@ron827]

Hard to believe a 3/4" square hole could get wollered out like that but not a problem for "The Master" to repair. Not many hobby shops have a 3/4" square broach!

[@glencoad737]

just a mere $482 from Fastenal for the broach.

[@Smallathe]

Awesome fix! Don't you love these little surprises (drill bits slipping... etc)? I find them frustrating but they do give me a light bulb moment from time to time. So no complaints on my part... LOL

[@sunny71169]

Kind of surprised that you didn't make another bushing after it spun while you were forming the hole for the set screw, or at least faced it off to make it look pretty.

[@Ujeb08]

The job of this "Dutch Key" is two fold. That is, it holds the part (the bushing in this case) in both the radial and axial direction with one simple screw. It's a great design as it is for low torque situations. many machinists install 2 set screws 180 degrees apart for higher torque situations. Also, I always try to make the part( bushing here) a press fit before installing the Dutch Key - that way it will not walk on you as you drill and tap the parts as it did on Keith at time 15:00

[@DoRiteFabrication]

If at first you don't succeed, drill drill again! Great fix, thanks for sharing Keith.

[@johnnyholland8765]

When in doubt just clamp it into submission.......It is the little details like that that make the difference. But then it is always that kind of repair that gets put off till "next time". Good looking machine you have there.

[@JRD77VET]

Nice fix and good for you to show the minor problem you encountered. A slightly different approach to clamping it down fixed the problem. Did you have the arbor table clamped? It seemed to be deflecting. Jeff

[@kc8bdr]

Quick and easy,

[@robertcorrie6737]

Can’t say enough about mechanical advantage and hydraulic power. Thanks

[@S3145]

The lathe looks great. Whatever happened with the noise in the gearbox?

[@waynep343]

How are the lead screws in the end cap lubed. Is that slot supposed to be stuffed with felt wick then an oring cut open and packed in slightly to prevent oil loss. With as many times as those might turn a minute. Also does bolt torque effect the gap width. Perhaps that's why it was so hard the drive off the ends.

[@Zerostar369]

Very nice Keith! Any idea when we might see an update to the radial drill table restoration?

[@j-man72b72]

Nice job, I am surprised you didn't braze the previous set screw cavities and repaint the end and arm(not the ball).

[@Bodi2000]

As you started drilling I thought "how did he keep it from turning?"... then it did. Lucky it wasn't deeper with the drill shattering and jamming hardened shreds in the gap.

[@JasonOfTGA]

heh, If only that Lathe could tell stories. Must have taken decades of use to woller out that bushing like that :)

[@kevinplowman8982]

Love the videos!!! Keep them coming but I was wondering do you have asthma

[@akfarmboy49]

K model is a nice lathe

[@dananelson479]

That' not a square hole. In a perfect world things go according to plan. That's why they make hand grenades and atom bombs, but a center drill will work. Feels good having it engage as designed. Broaching that hole looked like fun. Thanks for sharing.

[@hmshopfix6283]

Keith, during the broaching it looked like the press table was flexing a good bit. Is there a lock on the table to keep it stiff? Eric

[@nathanokun8801]

I forgot that the handle had to slide down the square rod. The locking pin would need to be a set screw going through one side of the handle and square-holed bushing, having a polished flat face that pushes against the square rod lightly so that it can slide along it, but still keep any rotation from happening. If the bushing is a hard material with a close tolerance for a tight fit to the rod, the set screw would never cause any sideways wear as the handle was moved in its position.

[@AustrianAnarchy]

Second Arbor Day of 2019!

[@rca7591a]

I noticed a lot of lathe owners make replacement parts for their machinery. FarmCraft101 made a chuck key for his Grizzly lathe.

[@infoanorexic]

I noticed that the shop still has an echo. You need more machines! ;-)

[@sansdecorum4600]

Would having removed the tailstock and moving the carriage towards the tail and shortening the unsupported shafting made removing the shaft/ screw bushing support bracket easier? Never pulled one apart, so I'm only speculating. Other than that inquiry, I really like the channel and the variety of projects taken on. So cool on so many levels. With work, travel, homelife, the museum, your own massive home-shop, projects, machine rebuilds, hosting scraping classes, and making videos; where do you find the time for it all? Do you not sleep? Are you able to manipulate space-time? Can't quite conjour how you fit it all in.

[@paulmace7910]

I’ve always heard those setscrew “keys” referred to as a “Dutchman”. Thanks for the vid.

[@leeklemetti1887]

That reminds me of the story of the Dutch boy, the leaky dam and his thumb in the leaky hole.

[@chowtownpiper]

First, great content Keith!

[@BobOBob]

I sure hope you tested to insure the "mystery steel" is softer than the square rod. That's going to wear a tiny bit with every single traverse, and you want it to.

[@melgross]

I would have used a small milling bit to make the hole as large as possible but just smaller than the drill for the tap. Milling bits don’t care that there are two different metals.

[@tehsimo]

its spinning in the handle because the drill is exerting a rotational force on it, and the axis of that rotational force is right at the edge.

[@crockteerden4023]

Using grub screws can be a challenge to keep the part from moving. I’ve had success by using a very small drill then stepping up.

[@jeffryblackmon4846]

Nice repair, Keith. However, you could have simply jammed in some shim stock and had a semi-permanent repair. Just thinking.... (sarc).

[@RichardHeadGaming]

Keith always has a handle on the situation.

[@vintagecarnews5899]

power video

[@panbayaer2288]

Hello I like your video, every good, I'm Chinese

[@SuperAWaC]

i want a nice monarch lathe with all the bells and whistles

[@MrPatdeeee]

Hi Keith. Why did you not do that also, with the same problem at the head-stock? Or that is what I thought I saw in an earlier video.. Am I incorrect?

[@ausshot83]

Another great video just one question why didn't you put the set screw in from the side of the handle

[@ardvarkkkkk1]

ausshot83 It's much stronger put in the way he did it. The screw is used as a threaded key. It's a rather old time thing and I was surprised to see it.

[@ausshot83]

@@ardvarkkkkk1 OK thanks my only question is how is it stronger (sorry I don't understand) that when a set screw could be screwed into the side and into the broached bearing for tight fit and it would also make it easy to readjust when the bearing wears out like the last one

[@outsidescrewball]

nice work, cool that you share the little issue...looked like the tap follower came from the “monkeys” Phil and Pierre...as I have one also

[@Copozeras]

I would have changed monarch's design approach on that. What about a dog point set screw from the side and a pre drilled dimple in the bushing? Its a shame that with the current design with every new bushing you have to drill and tap new thread. As I see there is few of them already.

[@Ujeb08]

The job of the "Dutch Key" (existing design) is two fold. That is, it holds the part in both the radial and axial direction with one simple screw. It's a great design as it is for low torque situations. many machinists install 2 set screws 180 degrees apart for higher torque situations. Also, I always try to make the part( bushing here) a press fit before installing the Dutch Key - that way it will not walk on you as you drill and tap the parts as it did on Keith at time 15:00

[@jeffaddison6332]

FAMCO knee bolts could use a tightening

[@SjwNz08]

Were you using standard oil or cutting oil on the broach?

[@peebee143]

Was there anything preventing you from making the bushing longer so it went further up inside the fixing bracket, thereby giving a greater load bearing surface?

[@erichockuly9819]

There is a set depth of the pocket…it is only 3/4” deep, but there is another bushing on the other side that needed replaced if there is that much play on the handle

[@cawensil3264]

A completely novice question... But... Why would you not weld up the predrilled holes and just make a keyway in both the handle and the bushing for squarestock with a side drilled set screw? Just seems to me to be a better way instead of having to drill a new set screw hole each time this part is replaced. (which seems to be quite often from the looks of the handle)

[@danielcobbins9050]

He could not weld steel to iron. Iron, being softer, would have to be brazed. An iron-steel weld would break apart.

[@cawensil3264]

@@danielcobbins9050 was not referring to welding the parts together. Simply filling all the other drilled holes and then broaching a keyway into the handle with a set screw from the outside and machining a keyway onto the sleeve.

[@migtrewornan8085]

a) it's quicker and easier just to do it this way and until you actually run out of space for new holes - why not b) a set screw and keyway would prevent the bushing from spinning but not prevent it working out of the handle

[@philliplopez8745]

Should have drilled and taped the handle . A set screw would allow adjustment of the handle .

[@OldtimeIronman]

Maybe krazy glue or loctite the center piece before drilling?

[@hilltopmachineworks2131]

I need to do the same repair to my Model K. I don't have a 3/4 square broach. Can I make the part and you broach it for me Keith?

[@0psi736]

I keep looking for mystery metal at the supply house but can never seem to find it.

[@billbaranko8907]

is there concern with the mystery metal wearing on the square shaft or is the machine too old or not enough use anticipted to care

[@cpad007]

Is it typical for broached holes to still have some round left?

[@the_hate_inside1085]

Wouldn't you want to make the bushing in something softer then steel, like cast iron, or brass, so that the wear is on the bushing, and not the shaft which is harder to replace?

[@zanechristenson3436]

An end mill probably would have been the way to go to start that hole